OPTIMIZATION OF MECHANICAL ANISOTROPY OF COVER SHEETS TO MINIMIZE THE POLYTHICKNESS WHEN STRETCH-WRAP FORMING


Cite item

Full Text

Abstract

Using the PAM-STAMP 2G software package, the authors carried out the computer simulation of the process of stretch-wrap forming of sheets with the varied mechanical anisotropy. To study the influence of mechanical anisotropy on polythickness, the authors used the central composite design that includes complete and fractional factorial experiments and a number of replicate experiments and depends on the number of factors. As the variable factors of the model, the following mechanical properties of the material were used: yield strength, flow limit, uniform elongation, and the Poisson’s rate.

After simulation of all variants of stretch-wrap forming, the regression analysis of the results was implemented and the mathematical model of polythickness dependence on the mechanical anisotropy was formulated. It is determined that to minimize the polythickness, it is necessary to position sheet workpiece in relation to the bed of press in such a way that the direction of stretch-wrap forming would be the same as the direction of maximum anisotropy index, and the transverse direction of the stretch-wrap forming would be the same as the minimum anisotropy index.

Using the known methods of searching the function global minimum, the authors determined the optimal mechanical anisotropy, which provides the minimum polythickness (19,62 µm) for the considering scheme of stretch-wrap forming of sheets made of 1441 aluminium-lithium alloy: yield strength – 430 MPa, flow limit – 280 MPa, uniform elongation – 14 %, the ratios of transverse deformation at the angle of 0° and 45° to the rolling direction – 0,65, at the angle of 45° – 0,35. The rolling direction is the same as the direction of stretch forming.

It is recommended to the enterprises to provide the input control not only according to the mechanical properties but according to the transverse deformation ratios as well because they influence greatly the obtaining of the required shape of the product.

About the authors

Sergey Viktorovich Surudin

Samara University, Samara

Author for correspondence.
Email: innosam63@gmail.com

PhD (Engineering), assistant of Chair of Pressure Metal Treatment

Russian Federation

Yaroslav Aleksandrovich Erisov

Samara University, Samara

Email: yaroslav.erisov@mail.ru

PhD (Engineering), assistant professor of Chair of Pressure Metal Treatment

Russian Federation

Ilya Nikolaevich Petrov

Samara University, Samara

Email: ilpetrof110895@yandex.ru

student of Institute of Space Rocket Engineering

Russian Federation

References

  1. Park J.-W., Kim J., Kang B.-S. Study on multiple die stretch forming for curved surface of sheet metal. International Journal of Precision Engineering and Manufacturing, 2014, vol. 15, no. 11, pp. 2429–2436.
  2. Seo Y.-H., Kang B.-S., Kim J. Study on relationship between design parameters and formability in flexible stretch forming process. International Journal of Precision Engineering and Manufacturing, 2012, vol. 13, no. 10, pp. 1797–1804.
  3. Wang S., Cai Z., Li M., Lan Y. Numerical simulation on the local stress and local deformation in multi-point stretch forming process. International Journal of Advanced Manufacturing Technology, 2012, vol. 60, pp. 901–911.
  4. Liu W., Yang Y.-Y., Li M.-Z. Numerical simulation of multi-point stretch forming and controlling on accuracy of formed workpiece. International Journal of Advanced Manufacturing Technology, 2010, vol. 50, pp. 61–66.
  5. Wang S., Cai Z., Li M. Numerical investigation of the influence of punch element in multi-point stretch forming process. International Journal of Advanced Manufacturing Technology, 2012, vol. 49, pp. 475–483.
  6. Chen X., Li M.Z., Fu W.Z., Cai Z.Y. Numerical simulation of different clamping modes on stretch forming parts. Advanced Materials Research, 2011, no. 189–193, pp. 1922–1925.
  7. Cai Z.-Y., Yang Z., Che C.-J., Li M.-Z. Minimum deformation path sheet metal stretch-forming based on loading at discrete points. International Journal of Advanced Manufacturing Technology, 2016, no. 4, pp. 1–10.
  8. He J., Xia Z.C., Zhu X., Zeng D., Li S. Sheet metal forming limits under stretch-bending with anisotropic hardening. International Journal of Mechanical Sciences, 2013, no. 75, pp. 244–256.
  9. Krupskiy R.F., Krivenok A.A., Stankevich A.V., Feoktistov S.I., Belykh S.V. Shaping profile blanks at a sheet stretch-forming press. Uchenye zapiski Komsomolskogo-na-Amure gosudarstvennogo tekhnicheskogo universiteta, 2013, vol. 1, no. 2, pp. 4–8.
  10. Mironenko V.V., Cheslavskaya A.A., Belykh S.V. Simulation of stretch-forming of airborne vehicle’ skin with regard to the effects arising in the zones of the workpiece blank clamping by jaws. Uchenye zapiski Komsomolskogo-na-Amure gosudarstvennogo tekhnicheskogo universiteta, 2014, vol. 1, no. 2, pp. 13–18.
  11. Malashchenko A.Yu. Finite element simulation of hybrid sheet part production. Vestnik Irkutskogo gosudarstvennogo tekhnicheskogo universiteta, 2013, no. 4, pp. 40–43.
  12. Krupskiy R.F., Krivenko A.A., Stankevich A.V., Belykh S.V., Mironenko V.V. Modeling motion kinematics of FET stretch forming press working elements. Vestnik Irkutskogo gosudarstvennogo tekhnicheskogo universiteta, 2014, no. 9, pp. 40–45.
  13. Belykh S.V., Krivenko A.A., Mironenko V.V., Mishagin V.A. Stretch die position determination in FET-type sheet stretch press workspace during preproduction engineering. Vestnik Irkutskogo gosudarstvennogo tekhnicheskogo universiteta, 2013, no. 12, pp. 36–41.
  14. Demyanenko E.G. A technique of shaping the barrel-type parts. Russian Aeronautics, 2014, vol. 57, pp. 204–211.
  15. Grechnikov F.V., Antipov V.V., Erisov Y.A., Grechnikova A.F. A manufacturability improvement of glass-fiber reinforced aluminum laminate by forming an effective crystallographic texture in V95 alloy sheets. Russian Journal of Non-Ferrous Metals, 2015, vol. 56, pp. 39–43.
  16. Erisov Y.A., Grechnikov F.V., Surudin S.V. Yield function of the orthotropic material considering the crystallographic texture. Structural Engineering and Mechanics, 2016, vol. 58, no. 4, pp. 677–687.
  17. Mikheev V.A., Smolnikov S.D., Surudin S.V., Savin D.V. Statistical analysis of stretch shaping process of biconvex skin. Russian Aeronautics, 2016, vol. 59, no. 1, pp. 145–150.
  18. Mikheev V.A., Grechnikov F.V., Dementev S.G., Samokhvalov V.P., Savin D.V., Surudin S.V. Simulation of kinematics scheme serial of shells stretchforming double-convex form on stretchforming press FEKD. Izvestiya Samarskogo nauchnogo tsentra Rossiyskoy akademii nauk, 2014, vol. 16, no. 6-1, pp. 172–179.
  19. Hill R. The Mathematical Theory of Plasticity. Oxford, Clarendon Press Publ., 1950. 365 p.
  20. Gronostajski Z. The Constitutive Equations for FEM Analysis. Journal of Materials Processing Technology, 2000, vol. 106, pp. 40–44.
  21. Samarskiy A.A., Gulin A.V. Chislennye metody [Numerical methods]. Moscow, Nauka Publ., 1989. 432 p.

Supplementary files

Supplementary Files
Action
1. JATS XML
Download

Copyright (c)



This website uses cookies

You consent to our cookies if you continue to use our website.

About Cookies